Sock and a method of knitting a sock

ABSTRACT

A method of creating a cushioned sock whereby a polymer cushion is positioned between an outer and an inner layer of yarn or fabric is provided. The method comprises horizontally positioning a first and a second layer of fabric, the first layer atop the second layer. The method also comprises attaching a first polymer cushion to the first layer tube about two inches from a left end. The method also comprises attaching a second polymer cushion to the first layer about five inches from the first polymer cushion and toward a center area of the layers. The method also comprises drawing a left half of the layers completely over the right half of the layers, the drawing action causing a full exterior surface of the left half to become an interior surface covering an exterior surface of a right half.

CROSS REFERENCE TO RELATED APPLICATIONS

The present non-provisional patent application is related to U.S.Provisional Patent Application No. 63/116,325 filed Nov. 20, 2020 andincorporates the contents thereof in full.

FIELD OF THE INVENTION

The present disclosure is in the field of foot apparel. Moreparticularly, the present disclosure provides systems and methods ofconstructing a sock with a polymer, elastomeric material, polyurethane,or gel patch or pad between an outer layer and an inner layer to createa cushioned sock at the ball and heel of the foot, the patch or padencapsulated between the outer and inner layers.

BACKGROUND

The ball and heel of the human foot support a significant amount oftotal body weight. When walking, running, climbing, and carryingobjects, the ball and heel bear even greater weight. Ankle, knee, back,and neck pain can be reduced by using quality footwear that providescushioning and protection. Such footwear includes socks in addition toshoes. A sock of high quality absorbs perspiration and also keeps thefoot warm.

SUMMARY

A sock and method of knitting a sock such that a gel or elastomericpolymer such as silicone is sandwiched between an outer and inner layerand whereby the sock is knit in one continuous tube or cylinder and thatwhen folded upon itself creates a double layer with the purpose ofcovering the adhered polymer between outer and inner layers. The polymeris sandwiched or surrounded by yarn, fiber, or thread layers. Thepolymer is provided in the form of two pads or patches that providecushioning for the foot and may extend the life of the sock. Variousmanufacturing systems and methods are provided herein, all based on anseveral common underlying principles.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a block diagram of a system of a double-layered sockcontaining polymer pads cushioning the ball and heel of the footaccording to an embodiment of the present disclosure.

FIG. 2 is a diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

FIG. 3 is a block diagram of a system of a double-layered sockcontaining polymer pads cushioning the ball and heel of the footaccording to an embodiment of the present disclosure.

FIG. 4 is a diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

FIG. 5 is a diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

FIG. 6 is a diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

FIG. 7 is diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

FIG. 8 is a diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

FIG. 9 is a diagram of a system of a double-layered sock containingpolymer pads cushioning the ball and heel of the foot according to anembodiment of the present disclosure.

DETAILED DESCRIPTION

Systems and methods described herein provide for producing adouble-layered sock made from a single tube of fabric or yarn or fromtwo separate tubes in which pads or cushions are positioned between twolayers and are not visible to a user. A first pad is positioned at aball area of the user's foot and the second pad is positioned at theheel area. The pads provide cushioning and comfort for the user atpoints where the user's weight rests most heavily. The pads may alsoextend the useful life of the double-layered sock.

The sock is produced from a single continuous tube of fabric that isfolded into itself to form two layers or from two separate layers thatare joined similarly. A first side or half of the tube is folded over tocompletely envelop a second side or half. As the far end orcircumference of the first half is pulled over and completely encasesthe second side, the second side may be pulled through the interior ofthe first side. The result of this action is a double-layered cylinderwhere one end must be sewn to close either a toe section or finalize awelt area at the top of the sock depending on placement of the siliconepads.

Prior to the folding and enveloping action described above, the twosilicone pads are placed on the side or half of the fiber tube that isclosed over atop the other side or half. The side holding the pads, oncefolded over, then faces inward to the outward facing surface of theother side. The toe or welt section may then be sewn depending on theoriginal placement of the pads as provided in separate but similarembodiments provided below.

The two pads are affixed to the fabric with adhesive. Silicone gel ismixed with 3% of its catalyst. Silicon is filled into a brass metallicmold in which a designed grid is engraved using a computer numericallycontrolled (CNC) machine. The mold is placed on the pattern knitted inthe inner layer of the sock. The mold is compressed in double plattedcompression machine. Heat of an upper plate is set to 105° C., and heatof a lower plate is set to 95° C. under air pressure of 2 HP for twominutes and 20 seconds.

Once the first half or side is folded and closed over atop the secondhalf or side, the double-layer sock with silicone pads affixed within isstretched over a foot form. The form is passed through temperature of160° C. for 20 seconds and applied air pressure of 2 HP.

Systems and methods provide that the two halves of the fabric tubebecome the two layers of the double-layer sock. Because the two halvesbegin as a single continuous fabric tube and are not physically cut orseparated, each of the two halves effectively comprises one of the twolayers of the sock. Before folding, the two layers are joined at eithera toe area or a welt area as is discussed in detail below in conjunctionwith the figures.

Turning to the figures, FIG. 1 is a block diagram of a system of adouble-layered sock. FIG. 1 depicts components of a system 100 of a sockand a method knitting a sock as provided herein.

As noted, the double-layered structure of the sock is made possible byfolding one half of a fabric tube or cylinder that is holding twosilicone pads over the other half of the tube. The present disclosureprovides for two embodiments which may be easier for an observer tounderstand by viewing FIG. 2 that provides detail for FIG. 1 and byviewing FIG. 4 that provides detail for FIG. 3 . As FIG. 2 and FIG. 4illustrate, the two halves, that when united by the folding orenveloping process to become the double-layered sock, appear beforehandto be two individual socks joined at either the welt or toe. FIG. 2 andFIG. 4 are provided as they may guide a viewer in examining FIG. 1 andFIG. 3 , respectively, where the basic components provided herein areenumerated.

FIG. 1 , which as noted corresponds to FIG. 2 , provides the system 100which comprises a fiber tube 102, a left half 104, a right half 106, aleft end 108, and a right end 110. The system 100 also comprises a firstpatch 112, a second patch 114, a center point 116, a left welt 118, anda right welt 120.

The two halves 106, 108 in FIG. 1 are connected at the center point 116near the welts 118, 120 as can be seen clearly in FIG. 2 . The firstpatch 112 is affixed to the left half 104 about two inches from the leftend 108 which is the toe area. The first patch 112 supports the ball ofthe user's foot. The second patch 114 is affixed to the left half 104about six inches to the right of the first patch 112 and support touser's heel.

After the patches 112, 114 are firmly affixed to the left half 104, theleft half 104 is pulled over the right half 106 in an enveloping mannersuch that the left half 104 entirely encases and contains the right half106. This action could be aided by pulling the right half 106 throughthe center point 116 and into the interior of the left half 104 as theleft half 104 is being closed over the right half 106.

The result of the folding and enveloping action described above is thatwhat had been the outward facing surface of the left half 104 that holdsthe patches 112, 114 is now facing inward and in direct contact with theoutward facing surface of the right half 106. The patches 112, 114 alsoface inward and are completely contained within the layers of the nowcontiguous right half 106 and former left half 104. Further, thecircumference of the left end 108 now entirely encircles thecircumference of the right end 110 at the toe portion of thedouble-layered sock. The two ends 108, 110 are stitched together whichcloses the toe area. At the other end, where the left welt 118 and theright welt 120 are now together at the opening of the double-layer sock,the two layers may be joined.

FIG. 2 provides a more detailed view of the components of FIG. 1 . Thetube 102, which in FIG. 2 is depicted as two socks joined at their weltareas, would not be shaped as socks during the manufacturing processdescribed above until the double-layer sock is sewn. The double-layeredstructure would be placed on a form shaped as a sock to receive shapingand further treatment and be finalized as a finished product.

FIG. 2 depicts what are shown as the left half 104 and the right half106 in FIG. 1 as an outer layer and as an inner layer, respectively.FIG. 2 also depicts components such as seam allowance, run guard, archsupport, transfer, and blister guard/Achilles support that add value tothe double layered sock but may not be directly relevant to systems andmethods provided herein. Further, while the patches 112, 114 aredescribed herein as silicone, they may alternatively or additionally bemade of other substances that may comprise gel, polyurethane, and/orother polymers.

FIG. 3 depicts components and interactions of a system 300 of adouble-layered sock. Components of the system 300 are indexed to thecomponents of the system 100. FIG. 4 supports and supplements FIG. 3 inthe same manner as FIG. 2 supports and supplements FIG. 1 .

As noted, discussion of components and interactions of FIG. 3 and thesystem 300 is supplemented by FIG. 4 . FIG. 3 depicts a second anddifferent embodiment from the embodiment provided by FIG. 1 and thesystem 100. Whereas in FIG. 1 the two halves 104, 106 are joined at atop or welt area and then closed together such that thereafter the toearea is to be sewn and closed, in FIG. 3 , the two halves 304, 306 arejoined at the toe and not at the top or welt as in FIG. 1 .

In FIG. 3 , the first patch 312 is proximate the center point 316 andthe second patch 314 is about six inches to the left of the first patch312. This structure is in contrast with that shown in FIG. 1 where theposition of the patches 104, 106 is opposite that shown in FIG. 3 .

When the left half 304 is folded over the right half 306 such that theright half 306 becomes enveloped into the left half 304 closing over theright half 306, the toe area is at the center point 316 in contrast towhat takes place in FIG. 1 . The left end 308 in this second embodimentwould encircle the right end 310 and together the left end 308 and rightend 310 when sewn together would form the welt area of thedouble-layered sock.

FIG. 5 illustrates another embodiment wherein a second layer sole andtoe cover may be added to a sock. The second layer would be pulled overthe sock in a right to left manner as depicted in FIG. 5 . The finishedproduct is shown in a smaller image in the righthand area of FIG. 5 .FIG. 6 provides further detail regarding structure and placement of thepatches.

Knitting Technique A is applicable to FIG. 1 , FIG. 2 , and the system100

Knitting begins at the toe of the sock and follows accordingly:

1. First a toe and run guard are knit allowing for seam allowance at thetoe opening followed by continuous knitting into the ball area, furtherknitting into the arch area, the heel and ankle area and then to the topopening (in a way that are known techniques of knitting a sock). Themachine then reverses the order of the knitting technique and does notcut or break at the first knitted portion but continues to a second sockor a continuous tube or cylinder comprising a first knit portion and asecond knit portion.

2. The machine does not cut or drop the sock, it continues to knit thetop opening, the ankle, the heel, the arch, the ball area, the toe areaand run guard and seam allowance in order to create two socks connectedat a fold line or a center point which divides the sock into two.

3. The sock is then steamed and shrunk for fit and allowed to dry ordried in a dryer if needed.

4. The extended sock or still-open-sock is then placed on a flat metalfoot board or 3D foot insert where the gel, silicone, elastomer, orother polymer is added to the ball of the foot and heel in a specifiedpattern.

Knitting Technique B is applicable to FIG. 3 , FIG. 4 , and the system300.

Knitting begins at the opening of the sock and follows accordingly:

1. First the sock opening and hem, transfer, or welt is knit. The ankle,then the heel, then the arch, then the ball, then the toe, then the runguard and toe seam allowance (as in the ordinary or known techniqueanyone trained in the art of sock knitting would understand).

2. The machine does not cut or drop the sock, it reverses the knittingsequence and continues to knit the toe seam allowance, toe run guard,toe area, ball area, arch area, heel area, ankle area, opening and asecond transfer, hem, welt, or end of sock.

3. The sock is then steamed and shrunk for fit and allowed to dry ordried in a dryer if necessary.

4. The extended sock or still-open-sock is then placed on a flat metalfoot board or 3D foot insert where the gel, silicone, elastomeric, orother polymer is added to the ball of the foot and heel.

In Knitting Technique B, the hem or top opening of the sock may becreated by knitting a finished welt or transfer and finished on themachine. It may also be left unhemmed or welt free and hemmed at thefinal process after polymer application. As an alternative to the knitin welt hem, the first layer and second layer of the sock may be joinedtogether at the opening of the sock with a cover stitch, overlock,double needle or flatlock stitch or other method of conventional sewingof stretch knits, socks, or footwear.

Knitting Technique C is applicable to FIG. 5

1. First the sock opening, and hem, welt, or transfer is knit. Theankle, the heel, the arch, the ball, the toe, the run guard, and toeseam allowance.

2. The machine does not cut or drop the sock, it reverses the knittingsequence and continues to knit the toe seam allowance, toe run guard,toe area, ball area and top of sock past one to two inches from the endof toes where they join the foot. At this point, the top of the sock,just past the toe, ends the knitting and finishes before the instep(remaining top of sock). The lower portion continues to knit through thesole, all the way to the heel, but not up to the Achilles.

3. The sock is then steamed and shrunk for fit and allowed to dry ordried in a dryer.

4. The extended sock or still-open-sock is then placed on a flat metalfoot board or 3D foot insert where the gel, silicone, elastomer, orother polymer is added to the ball of the foot and heel onto the firstportion of the sock.

5. After the polymer is applied, the second partial portion is pulledback onto the sock and stitched into place covering the ball and heel.It is stitched in a manner that those skilled in the art of knitting orsewing would understand.

6. The toe seam is closed.

Knitting Technique D is applicable to FIG. 6 . A polymer cushion may beincorporated as thread.

The polymer may be incorporated into the knit structure by splicing apolymer, elastomeric, or silicone-based thread or monofilament at theareas of desired cushion during the knitting process. The material couldbe silicone, polymer, elastomeric polymer, gel, or polyurethane.

As the machine knits portion or sock at the ball or heel of the foot,whichever comes first, the knitting machine will be programmed to splicein a polymer yarn (as described above) such that added cushion isapplied but cover yarns are used to encase the thread or yarn inside ofthe traditional cover yarns like nylon, polyester, or cotton or otherknown natural or synthetic yarns.

1. The sock is knit single layer beginning at the top opening of thesock or toe. If the toe, the knitting technique will be reversed, butthe splicing technique or splicing areas would remain the same.

2. The hem, welt, or top opening finish is knit followed by any legportion of the sock and the ankle.

3. After the ankle, at the heel, a covered, elastomeric yarn is splicedin to create padded loops as in a terry cloth or piled knit structure.The elastomeric yarn acts as a cushion.

4. The elastomeric polymer can be covered with any commercial yarn,synthetic or cotton such as nylon, polyester, cotton, rayon, cellulosicfiber, or other known yarn used in sock making.

5. The covered elastomeric polymer is spliced in at the heel.

6. After the spliced polymer is added the sock continues to knit theinstep and sole.

7. At the sole and instep where the arch is, a specified denier is addedwhich is heavier than what is in the base layer of the sock to providearch support.

8. After the arch support, the ball area is knit by splicing in thecovered elastomeric polymer in the specified area.

9. The toe area is knit without the covered polymer.

10. The toe is closed.

11. The sock is steamed and dried.

12. The sock is boarded.

The polymer is applied in one of four ways.

Application method #1

The polymer is applied as a viscous, spreadable gel formula as a screenprint.

1. The sock is pulled onto a metal flat form or 3D form.

2. A metal plate with cut-outs of the shape of the desired end resultshape and thickness is placed over the sock.

3. An arm or spatula spreads the polymer over the metal plate which isabove the sock.

4. The sock is then coated with the polymer in the shape desired.

5. If multiple thicknesses of the polymer are desired, the polymer maybe coated onto the sock in a series until the desired thickness isachieved.

6. If multiple patterns are required, there may be the need for multiplemetal plates and a curing time between each one.

Application method #2

The polymer may be applied in a solid form by adhering the polymer shapedirectly onto the sock.

1. The sock is pulled onto a metal flat form or 3D form.

2. A premade and cured polymer shape or sheet is placed onto the ball orheel or specified area of the foot and pressed and/or heat set intoplace.

Application method #3

The polymer may be applied through hot melt method.

1. The sock is pulled onto a metal flat form or 3D form.

2. A mechanical strainer is used to press the viscous polymer directlyonto the sock in the desired shape and thickness.

3. The sock is then coated with the polymer in the shape desired.

4. If multiple thicknesses of the polymer are desired, the polymer maybe coated or hot melted or applied onto the sock in a series until thedesired thickness is achieved.

5. If multiple patterns are required, there may be the need for multiplepattern strains and a curing time between each one.

In the above application methods 1, 2, and 3, once the polymerapplication is cured and set, the sock is then closed by pulling thesecond portion of the sock onto the first portion of the sock. Thisencapsulates the polymer in between two layers.

Polymer as thread, yarn, or fiber:

1. An elastomeric polymer in the form of thread, fiber or yarn isthreaded onto the knitting machine.

2. It will be covered, braided, plied, wrapped, or placed with othercommercial synthetic or natural yarns.

3. The elastomeric polymer thread will be spliced into the sock at theheel or ball or as specified by the sock design.

The sock is then closed at the toe seam and is closed at the topopening, if necessary; and if needed, a stabilizing stitch is sewn atthe top opening to avoid slippage for application methods 1 and 2.

Knitting Structure (Yarn combination in another section) for applicationmethods 1 and 2:

The first knit portion may contain a yarn combination inclusive of allneedle heads or feeds of which some will drop out or less feeds will beincluded in the second sock portion.

The first sock portion or the portion which will be visible to thewearer when on body:

The toe portion will be a jersey knit structure containing a yarncombination of elastane, synthetic, and or natural fibers and anycomposition of those thereof. The toe portion contains the followingsections:

Seam allowance for stitching toe seam Run guard for protection fromtoenails, stitching of toe seam and general wear at toe seam.

Sock body beginning:

The run guard and seam will be a jersey knit with wales and courses of aspecified range but could also be an alternative knit structure.

The sole at ball and heel will be jersey knit (or other known knittingstructure) with wales and courses of a specified range and can utilizethe full needle head or feeds.

The arch of foot will splice in a spandex denier stronger or higher thanin the body of the sock or utilize a tighter knitting structure for archsupport. The spandex range at the arch may be a range of 20 denier to210 denier and a specified range of wales and courses.

Front and back of sock (if sock covers the lower leg) will be jerseyknit or any other known or suitable knit structure and cuff may beribbed or any other known or suitable knit. The top of instep will be apique, jersey, or other knit stitch and cover the top of the foot.

The second knit portion will be knit with a lighter weight or finer yarnor yarn combination in comparison to the first portion for the sock notto be thicker when doubled than a traditional sock worn by consumers forrunning, walking, or wearing shoes.

The run guard and seam may be a jersey knit (or other known knitstructure) with a specified range of wales and courses.

The sole at ball and heel will be jersey knit (or other known knitstructure) with a specified number of wales and courses and can utilizethe full needle head or feeds.

The arch of foot will splice in a spandex denier higher than that usedin the first portion of the sock or tighter knitting structure for archsupport.

Front and back of sock (if sock covers the lower leg) will be jerseyknit and cuff may be ribbed. The top of instep will be a pique, jersey,or other knit stitch and cover the top of the foot.

The sock may be knit with any knit structure regularly used by anyoneknowledgeable in the art of sock knit structures in various combinationsof areas, yarn combinations, and knit structures and can vary by area ofthe sock.

Polymer Structure:

The polymer structure is comprised of an elastomeric material formedinto a specific geometric pattern. This custom geometric pattern isdesigned in such a way to fit naturally to the shape of the sock and beeasily compatible with the polymer application methods listed above.

The design of this geometric pattern is such that the resulting gridpattern allows for adequate air and moisture transfer while providinglocalized support in key pressure point areas. The thickness of thispolymer structure is either a varying thickness or an even thickness,with then intent to further accommodate the key pressure point areas.

The specific material or material compound used to create this polymerstructure will have the following material properties:

-   -   Hardness: (Shore 00-0) to (Shore A-40)    -   Compressive Strength: 5 MPa to 35 MPa    -   Water Absorption: No greater than 3.00%    -   Density: No greater than 4.50 g/cc    -   Linear Shrinkage: No greater than 0.35 mm/mm    -   Modulus of rigidity (20° C.): No greater than 1.00 MPa

These material properties may be achieved by utilizing materialsincluding, but not limited to, the following:

-   -   Ethylene Propylene Diene Monomer (EDPM)    -   Natural Rubber (NR)    -   Silicon Rubber    -   Neoprene Polymer    -   Urethane Rubber    -   Polyurethan Rubber

The geometric pattern can be scaled as needed to accommodate thespecific application method used. Following the polymer application, theresulting polymer structure should match the pattern design shown below,with a maximum allowable deviation tolerance of 2.00%.

Once the polymer application has been completed, the resulting polymerstructure provides a targeted stress distribution, minimizing specificpressure points and providing a padded cushion while effectively andevenly spreading the pressure outward across the structure.

The maximum thickness of this polymer structure is not to exceed 2.00mm. This ensures the end product maintains flexibility and aestheticcharacteristics consistent with a standard sock and is not adverselyimpacted by machine washing or extended wear.

Cushion Technology:

-   -   A. Applied as molded solid structure    -   B. Applied as printed viscous gel or liquid    -   C. Applied as thread, fiber, or yarn    -   Polymer cushion incorporated as thread.

The polymer may be incorporated into the knit structure by splicing apolymer, elastomeric, or silicone-based thread or monofilament at theareas of desired cushion during the knitting process.

As the machine knits portion or sock at the ball or heel of the foot,whichever comes first, the knitting machine will be programmed to splicein a polymer yarn such that added cushion is applied but cover yarns areused to encase the thread or yarn inside of the traditional cover yarnslike nylon, polyester, or cotton or other known yarns.

Yarn Combination:

The first and second half of the sock is made of a combination ofsynthetic and natural yarn twisted, braided, bundled, or covered withspandex or elastane. The sock may be combinations of the following:

-   -   Nylon, polyester, cotton, spandex    -   Nylon, rayon, polyester, spandex    -   Bamboo, rayon, polyester, spandex    -   Nylon, cotton, spandex    -   Polyester, cotton, spandex    -   Cotton and spandex    -   Covered spandex    -   Bare spandex    -   Commercial blends of all natural, all synthetic, or a        combination of synthetic and natural fibers including cellulosic        fibers.

FIG. 7 , FIG. 8 , and FIG. 9 are illustrations of the polymer pad. FIG.9 depicts portions of the pad including small and large grid sectionsand load transfer structure of a typical pad.

While a substantial portion of the discussion herein describes astructure in which the polymer pad is knit in a continuous tube orcylinder, that in embodiments may be about 24 inches in length prior tothe drawing action, the structure provided herein may also becharacterized as the polymer pad being knit such that there may be twolayers to encapsulate the pad. In embodiments, the processes describedat length above regarding one half of the single tube being folded overand enveloping the other half of the tube with the polymer padssandwiched within may not be used. In some alternative embodiments, thesingle tube may not be used, and the process may instead begin with twoseparate tubes of equal or non-equal size. The polymer pads may beattached to one of the tubes using the methods described herein. Thetube with the polymer pads may then be made to cover over the other tubeusing various methods or be placed inside of the other tube using othervarious methods. The two separate tubes may then be joined via stitchingor other known method.

In an embodiment, a method of creating a cushioned sock whereby apolymer cushion is positioned between an outer and an inner layer ofyarn or fabric is provided. The method comprises horizontallypositioning a first and a second layer of fabric, the first layer atopthe second layer. The method also comprises attaching a first polymercushion to the first layer tube about two inches from a left end. Themethod also comprises attaching a second polymer cushion to the firstlayer about five inches from the first polymer cushion and toward acenter area of the layers. The method also comprises drawing a left halfof the layers completely over the right half of the layers, the drawingaction causing a full exterior surface of the left half to become aninterior surface covering an exterior surface of a right half. Acushioned sock is created whereby the polymer cushions are positionedbetween an outer and an inner layer of yarn or fabric. A sewing actioncloses the left half atop the right half. An opening at an end oppositea toe area comprises a welt area is not sewn and promotes insertion of afoot of a user. The first polymer cushion is positioned at a ball areaof the foot and the second polymer cushion is positioned at a heel areaof the foot. The drawing action results in the polymer cushions to besandwiched between the layers. The polymer cushions are made from atleast one of silicone, gel, polyurethane, and at least one additionalpolymer. The first layer and the second layer are about twenty-fourinches in length. Based on the drawing action, the first polymer cushionand the second polymer cushion are encased between the layers.

1-30. (canceled)
 31. A double-layer cushioned sock comprising a firstexternal layer positioned over a second internal layer with a firstpolymer cushion located between the first layer and the second layer andpermanently attached to either one or both the first layer and thesecond layer, the double-layer cushioned sock is produced by: providinga lay-flat tubular fabric shaped from a first end to a second end as afirst layer side transitioned to an inverse mirror-shaped second layerside, permanently attaching a first polymer cushion to either the firstlayer side or the second layer side, drawing the first layer sidecompletely over the second layer side to invert thereof such that anexterior surface of the first layer side becomes an interior surfacecovering entirely an exterior surface of the second layer side, therebythe tubular fabric forms a double-layer structure, and attaching thefirst end to the second end.
 32. The double-layer cushion sock as inclaim 31, wherein a transition between the first layer and the secondlayer defines a center of the lay-flat tubular fabric, and wherein thefirst polymer cushion is positioned about two inches or about six inchesaway from the center of the tubular fabric.
 33. The double-layer cushionsock as in claim 31, wherein the first polymer cushion is positioned ata ball area of the sock or a heel area of the sock.
 34. The double-layercushion sock as in claim 31 further comprising a second polymer cushionbetween the first layer and the second layer, both polymer cushions arespaced apart along the sock.
 35. The double-layer cushion sock as inclaim 34, wherein the first polymer cushion is positioned at the ballarea of the sock and the second polymer cushion is positioned at theheel area of the sock, thereby forming a double-layer sock with a ballof foot and heel support.
 36. The double-layer cushion sock as in claim34, the first polymer cushion is positioned about two inches away fromthe center of the fabric, and the second polymer cushion is positionedabout six inches away therefrom.
 37. The double-layer cushion sock as inclaim 31, comprising a welt area to facilitate insertion of a foot of auser.
 38. The double-layer cushion sock as in claim 31, wherein thefirst polymer cushion is made from at least one of silicone, gel, orpolyurethane.
 39. The double-layer cushion sock as in claim 38, whereinthe first polymer cushion further comprises at least one additionalpolymer.
 40. The double-layer cushion sock as in claim 31, wherein thelay-flat tubular fabric is produced by knitting.